Eurocal COUNTRYMAN Installation & User Manual Download Page 1 | Manualshive

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Eurocal COUNTRYMAN Installation & User Manual Download Page 1

Installation & Users Guide

SENATOR
and
COUNTRYMAN
System- Boilers

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Summary of Contents for COUNTRYMAN

Page 1: ...Installation Users Guide SENATOR and COUNTRYMAN System Boilers ...

Page 2: ...RMED PIPE WORK 10 SEALED SYSTEM 10 PLASTIC PIPE 10 CAPACITIES OF EXPANSION VESSEL 11 EXPANSION VESSEL SIZING 11 WARNING SEALED SYSTEM 11 FILLING SYSTEM 11 SENATOR CONVENTIONAL FLUE INSTALLATION 12 BALANCED FLUE INSTALLATION INTERNAL 13 21 CONNECTING OIL SUPPLY 21 22 ELECTRICAL CONNECTION INTERNAL EXTERNAL 23 WIRING DIAGRAM INTERNAL 23 TECHNICAL DATA BOILER SPECIFICATIONS 24 25 COMMISSIONING INSTRU...

Page 3: ...ARRANTY MAY BE INVALID Warranty on the Heat Exchanger 5 Years Warranty on Burner and Controls 2 years CONDITIONS OF WARRANTY 1 Boiler MUST BE installed by an OFTEC registered engineer if not permission will be required by building control 2 Boiler MUST BE commissioned after installation by an OFTEC registered engineer 3 Boiler MUST BE serviced every 12 months after installation by an OFTEC registe...

Page 4: ...the burner will occur when the water temperature within the boiler falls below the control thermostat set point which will continue to run until the water temperature rises to the temperature recommended set on the boiler control thermostat SWITCHING THE BOILER ON Check there is water in the system Check radiator valves are on Turn on oil supply Switch electrical supply to the boiler on including ...

Page 5: ...s this will precipitate corrosion thus reducing the life of the boiler HIGH LIMIT STAT INDICATOR The high limit lockout will occur when the water within the boiler is or has overheated e g reached a temperature above that set on the high limit thermostat TO RESET THE BOILER When the boiler has had time to cool the manual reset button coloured red on the control panel will need to be pressed in to ...

Page 6: ...tion of the boiler and can be attributed to following examples An interruption of the fuel supply Electrical Supply fault e g Extreme low voltage Failure of a Burner component A fault within the heating system Burner combustion not being correct The Burner Reset button on the Control Box and the red Lockout Indicator on the boiler control panel illuminates to indicate that a lockout has occurred I...

Page 7: ...el will go out and the burner will commence the ignition start sequence After 15 seconds the Burner should fire normally PLEASE NOTE Should the Burner not start both lockout indicator on the Control Panel and Burner Reset Button will illuminate again Wait at least 3 minutes and depress the Burner Rest Button again Failure to start a second time indicates a fault requiring attention In the event of...

Page 8: ...ctrical Regulations BS7074 Code of practice for sealed systems Building Regulations Part L1 and J 2002 England and Wales Part F Scottish Regulations and Technical Booklet L Northern Ireland OFTEC Codes of Practice Published or Recommended After installing the system it needs to be flushed with a cleanser like Fernox Heavy Duty Restore for fast acting removal of lime scale black sludge magnetite an...

Page 9: ...tary pipework 600 F From an internal or external corner 600 G Above ground or balcony level 600 H From a surface or a boundary facing the terminal 600 J From a terminal facing the terminal 1200 K Vertically from a terminal on the same wall 1500 L Horizontally from a terminal on the same wall 750 M Above the highest point of an intersection with the roof 600 N From a vertical structure on the side ...

Page 10: ...loadings CONTROL PANEL The boiler control panel is factory fitted prior to despatch The phials of the Control and High Limit Thermostat are inserted into the horizontal pocket situated on the left hand side of the boiler heat exchanger 9 DIAGRAM OF PHIAL POSITIONS ON BOILER HEAT EXCHANGER ELECTRICAL ENTRY The electrical supply to the boiler must be 230 volts 50 Hz fused at 5A Connection of the app...

Page 11: ...A pressure relief valve operating at 3 bar is fitted The over flow pipe must terminate in compliance with current building regulations This boiler is supplied with a 12 litre expansion vessel It is the installers responsibility to ensure adequate provision is made for expansion within the heating system and to install extra capacity if required Damage to components caused by over expansion may not...

Page 12: ...stems EXPANSION VESSEL SIZING Having determined the total system water content expansion vessel sizing can be considered Taking into account the other system design factors Full details of expansion vessel sizing and Altecnic models available are given in the expansion vessel data sheet However Altecnic expansion vessels are supplied pre charged at 1bar suitable for system static heads up to 15 me...

Page 13: ...and brick chimney is recommended to minimize the occurrence of condensation 5 Cowls Cowls and pots that may restrict the flue should not be used 6 Draught Stabiliser Chimneys over 6 metres high may produce excessive draught over 4mm w g Draught stabilizers may be required 7 Length Before bends are applied length of flue must be at least 600mm COMBUSTION AIR SUPPLY CONVENTIONAL FLUE 12 INFORMATION ...

Page 14: ...COMBUSTION AIR SUPPLY BALANCED FLUE BOILERS 550mm kW 2 550mm kW 2 BOILER IN COMPARTMENT VENTED FROM OUTSIDE 1100mm kW 2 1100mm kW 2 180 TO 450 B C SIDE OUTLET LEFT 180 TO 450 B REAR OUTLET LOW LEVEL BALANCED FLUE NOTE If flueing from the side of the boiler Combi preformed pipes must go opposite to the side on which the flue is flueing from NOTE If flueing from the right hand side of the boiler whe...

Page 15: ...boiler 3 Fit Red inner seal and Black out Seal to flue connector and extension if required 4 Apply lubricant included in kit To the inner and outer seal taken care to only lubricant the lip of the seal MODEL Flue A B C D 50 70 3 125 176 765 130 70 90 3 125 176 765 130 REMOVE CASING LID TEST POINT TERMINAL GUARD A Terminal Guard must be fitted to low level Flue Terminal below 2 metres and where per...

Page 16: ...on kits 3 x kit 3 300mm extension OR 1 x kit 6 950mm extension 8 Remove CF adaptor from burner and discard 9 Fit the gasket and B F adaptor and connect snorkel Tube N B Kit 8 45 degree bends must not be used on low level balanced flue kits 15 HORIZONTAL FLUE FIT BOLTS FIT SNORKEL TUBE FIT CLIP INTERNAL VIEW ITEM DESCRIPTION PART No 1 Control Thermostat COTHCS 2 High Limit Thermostat COTHHL 3 Safet...

Page 17: ... boiler and Cut Hole in wall Remember measure mark CHECK then cut 2 Remove Conventional flue ring from top of boiler REMOVE CASING LID REMOVE FOIL REMOVE FLUE RING FIT SEALS AND LUBRICATE BOLT BOTTOM SECTION TO BOILER TEST POINT MODEL Flue A B C 50 70 3 125 176 200 70 90 3 125 176 200 50 115 700 1100 mm ...

Page 18: ...ntal section and pass through the wall Making sure that the terminal protrudes through the wall a minimum of 176mm 10 Connect vertical and horizontal section together 11 Secure vertical section with the screws provided 12 Seal around the flue terminal in wall using mastic 13 Remove CF adaptor from burner and discard 14 Fit BF adaptor connect snorkeltube with clip NOTE Expanding foam can be used to...

Page 19: ...l flue is telescopic as supplied The flue has a range of 1020 2400mm from the top of the boiler to the flashing Extension kits of 300 and 950mm are available The maximum vertical length is 4800mm Also available are 45 degree bends For further information contact our sales office N B Every 45 degree elbow is equivalent to 500mm of flue ...

Page 20: ...h the clip 7 Refit boiler top panel insure the knock out in the panel has been removed 8 Assemble second vertical flue section and any vertical extension 9 Fit the roof flashing and flue terminal 10 Secure the terminal to a roof joist with clamps provided 11 Fit flue elbows if required and secure vertical section with the screws provided 12 Seal around the flue terminal in wall using mastic 13 Rem...

Page 21: ...ADAPTOR 20 Disconnect Burner Plug Fit B F Adaptor Fit B F Adaptor Gasket Peel backing sticky from B F adaptor Gasket Remove C F Adaptor Tighten bolt on burner Fit snorkel tube Internal view Loosen Bolt Remove Burner ...

Page 22: ... 80mm 5 VERTICAL FLUE KIT5 80mm 6 950 MM FLUE EXTENSION KIT6 80mm 7 45 DEGREE BENDS KIT8 80mm N B Kit 8 45 degree bends must only be used on kit 5 vertical flue kits 21 OIL FULL LEVEL OIL LOWEST LEVEL VENT FILL SIGHT GAUGE OIL TANK Plastic tank shown Steel tank also suitable FIRE VALVE ALTERNATIVE FILTER POSITION VALVE PAPER ELEMENT FILTER BURNER BOILER BEST POSITION FOR FIRE VALVE SENSOR REMOTE F...

Page 23: ... UPRIGHT 2 OUTSIDE RESIDENCE Can be above or below burner VALVE FILL VENT OIL FULL LEVEL OIL LOWEST LEVEL OIL LEVEL FULL OIL LOWEST LEVEL FIRE VALVE OIL TANK Plastic tank shown steel tank also suitable A flexible oil pipe is supplied to connect the burner to the incoming oil supply pipe IMPORTANT NOTES If siting oil tank above burner height use single supply pipe only If siting oil tank below burn...

Page 24: ... wired using a double pole isolating switch 240v 50hz fused at 5 amps A multi 3 pin plug is included with the boiler which connects with the boiler control panel The burner is supplied with 3 wire cable plug which allows disconnection for maintenance 23 INTERNAL SYSTEM BOILER WIRING DIAGRAM ...

Page 25: ...Ltr General Data Electrical Supply 240v 50Hz Oil Supply Connection 1 4 BSP Fuel 28 second or 35 second High Limit Stat Manual Reset Maximum Control Thermostat Setting 85 C Maximum Operating Pressure Expansion Vessel Capacity 12 Litres Spring Safety Valve 3Bar Conventional Size 100 125 mm Water Content Discharge Cold Mains Heating Flow Heating Return N B Heating Return option left or right ...

Page 26: ... Specification General Data Electrical Supply 240v 50Hz Oil Supply Connection 1 4 BSP Fuel 28 second High Limit Stat Manual Reset Maximum Control Thermostat Setting 85 C Maximum Operating Pressure Expansion Vessel Capacity 12 Litres Spring Safety Valve 3Bar Water Content DIMENSIONS IN MM N B Heating Return option left or right I Discharge H Cold Mains G Heating Flow F Heating Return ...

Page 27: ...also check settings between face of nozzle to diffuser plate Please refer to Burner technical manual for correct settings Fit manifold pressure gauge to the gauge port of the burner Turn electrical supply to the boiler to ON Set the central heating controls so they are calling for heat Set the boiler control thermostat to 80 C Purge air from the oil supply system Set burner pump pressure Allow tim...

Page 28: ...lean burner assembly and replace nozzle and change flexi oil line if required Renew insulation e g inspection door or inside base of heat exchanger if required Reassemble baffle assembly and replace inspection door Fit manifold pressure gauge to the gauge port of the burner Turn electrical supply to the boiler to ON Set central heating controls so they are calling for heat Set burner pump pressure...

Page 29: ... time clock is calling for heat Mains indicator green should be illuminated If green light is not illuminated and fuse has been checked then heating system charge may be low check black needle on pressure located inside boiler cabinet top right hand side is reading 1 bar or more If not repressurize refer to fault diagnosis on page 32 28 ...

Page 30: ... ITEM DESCRIPTION PART No 1 Reset Button N A 2 Control Box LOA24CBOX 3 Ignition Transformer STREBI 4 Ignition Cables STRHT 5 Nozzle Assembly N A 6 Nozzle NOZZ011 7 Brake Plate N A 8 Blast Tube ST40STR40BLAST Blast Tube ST 50STR50BLAST 9 Ignition Electrodes STRMONO 10 Connecting Pipe N A 11 Air Damper N A 12 Solenoid Valve DANCOIL 13 Pump DANBFP11L 14 Drive Coupling STRCOUP 15 Indication Air Damper...

Page 31: ... 0 65 80 S 80 S OIL PRESSURE BAR 9 5 10 FIRING RATE Kg hr 1 95 2 44 AIR SETTING APPROX SCALE No 12 14 SMOKE 0 0 Co2 12 12 5 FLUE GAS TEMP Less Minimum Temp Maximum Temp Ambient C 160 C 260 C These figures are to be used as a guide Site conditions may require adjustment to achieve most efficient combustion Bacharach Scale ...

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Page 34: ...and neither the manual nor any part may be reproduced without permission Turkington Engineering Limited have a continuing research and development programme which occasionally necessitates changes to specifications herein It is therefore essential that instructions issued with each individual appliance are carefully read prior to installation and strictly adhered to during installation The statuto...

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